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Home › Chevrolet › 2004 › Optra5 Base, Standard › Repair and Diagnosis › Transmission › Manual Trans › Manual Transmission - D20 › Repair Instructions › Transmission Replacement › Installation Procedure

Installation Procedure

    Fig 1: View Of Transaxle And Support Jack
    GM1248195Courtesy of GENERAL MOTORS CORP.
  1. Support the transaxle with a transaxle support jack.
  2. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.
    3. Fig 2: View Of Lower Transaxle And Retaining Bolts With Torque Specifications
    GM1245845Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the 7 transaxle lower retaining bolts.

    Tighten: 

    • Tighten the transaxle lower retaining bolts (1) to 73 N.m (54 lb ft)  .
    • Tighten the transaxle lower retaining bolts (3) to 21 N.m (15 lb ft)  .
    • Tighten the transaxle lower retaining bolt (2) to 31 N.m (23 lb ft)  .

    4. Fig 3: View Of Upper Transaxle Retaining Bolts
    GM1248197Courtesy of GENERAL MOTORS CORP.
  4. Install the 3 transaxle upper retaining bolts.

    Tighten:  Tighten the transaxle upper retaining bolts to 73 N.m (54 lb ft)  .

    5. Fig 4: View Of Transaxle Mounting Bracket And Bolts
    GM1248198Courtesy of GENERAL MOTORS CORP.
  5. Install the cage retaining bolt and cage.
  6. Install the 3 transaxle upper mounting bracket bolts and bracket.

    Tighten:  Tighten the transaxle upper mounting bracket bolts to 48 N.m (35 lb ft)  .

    7. Fig 5: View Of Rear Damping Block And Bolts
    GM1290979Courtesy of GENERAL MOTORS CORP.
  7. Install the 2 rear damping block retaining bolts.

    Tighten:  Tighten the rear damping block retaining bolts to 68 N.m (50 lb ft)  .

  8. Install the rear damping block from the front cross member.
    9. Fig 6: View Of Rear Mounting Bracket And Bolts
    GM1248201Courtesy of GENERAL MOTORS CORP.
  9. Install the 3 rear mounting bracket bolts and the bracket.

    Tighten:  Tighten the rear mounting bracket bolts to 90 N.m (66 lb ft)  .

  10. Install the damping block connection nut and bolt.

    Tighten:  Tighten the damping block connection nut and bolt to 68 N.m (50 lb ft)  .

    11. Fig 7: View Of Clutch Release Cylinder Pipe
    GM1290980Courtesy of GENERAL MOTORS CORP.
  11. Connect the clutch release cylinder pipe.
    12. Fig 8: Identifying Backup Lamp Switch And Speedometer Speed Sensor Electrical Connector
    GM1248184Courtesy of GENERAL MOTORS CORP.
  12. Connect the speedometer speed sensor electrical connector.
  13. Connect the backup lamp switch electrical connector.
    14. Fig 9: View Of Transaxle Rear Mounting Bracket And Fixing Shaft Pin
    GM1248179Courtesy of GENERAL MOTORS CORP.
  14. Remove the J 28467-B  (DW-117).
  15. Install the drive axle shaft. Refer to Front Drive Axle Inner Shaft Replacement (Manual) or Front Drive Axle Inner Shaft Replacement (Automatic) in Front Drive Axle.
  16. Install the shift linkage assembly. Refer to Shift Control Linkage Replacement .
  17. Install the battery and battery tray. Refer to Battery and Battery Tray Replacement in Engine Electrical.
  18. Inspect the fluid level. Refer to Transmission Fluid Level Inspection .
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